Package with pressure activated expansion chamber

ABSTRACT

A package having an expansion chamber is depicted and described. The package generally includes a collapsed expansion chamber configured to open when a predetermined amount of internal pressure is reached. A pressure sensitive closure mechanism, such as a frangible seal or flexible we film web, is disposed between the main compartment and the expansion chamber and functions to separate the main compartment and the expansion chamber until the predetermined internal pressure is reached.

PRIORITY

This application claims priority benefit of U.S. Provisional Patent Application No. 61/243772, filed on Sep. 18, 2009, and U.S. Provisional Patent Application No. 61/311110, filed on Mar. 5, 2010, both of which are hereby incorporated by reference herein in their entirety.

FIELD

The present invention relates generally to flexible packaging and, more particularly, to packages, and methods for forming and using packages, having expansion chambers actuated by pressure within the primary package chamber.

BACKGROUND

Flexible packages are used for containing a wide variety of items, both solid and liquid, such as beverages, lawn products and food products. Some products, such as carbonated drinks, produce gasses (gas off) during and after they are filled into a package. Conventional flexible packages have a fixed maximum volume, and therefore, cannot expand. As a result, the gas produced in the sealed package raises the pressure inside of the package. Some packages may fail because they are not strong enough to handle the additional pressure generated by the gassing off of the product once sealed. This is especially true with flexible packages. The use of flexible packages has been limited because of the limited pressures they can handle before failure.

Using vents in the flexible package is not always feasible. For example, some carbonated products, such as beer, require the carbonation or gas to stay within the container when it gases off. A vent would cause the gas to escape. Loss of the gasses may negatively affect the freshness, flavor and texture of the product. Vents are also an additional expense and are difficult to implement for products that require the package to be filled completely to the top, leaving no room for oxygen in the package. Oxygen may permeate the package through the vent, thereby negatively affecting the freshness of the product.

Package failure with increased internal pressure may also occur at or adjacent to a fitment or pour spout, such as the edges or seals where panels or joined. These seals, especially near where the ends of the fitment meet the two adjacent panels of film, tend to be the weakest section of the pouch, or where failures often occur.

As a result, there is a need for a flexible package that substantially solves the above-referenced problems with conventional package designs, configurations, and manufacturing methods.

SUMMARY

The present invention addresses certain problems facing flexible packages and the packaging industry. Embodiments of the present invention are directed to a flexible package having an interior compartment capable of storing a product, including solids or liquids. The package includes a collapsed expansion chamber configured to communicate with the interior compartment when a predetermined amount of internal pressure is reached. A pressure sensitive closure mechanism, such as a flexible film web or a frangible seal, is disposed between the interior compartment and the expansion chamber and functions to separate the main compartment and the expansion chamber until the predetermined internal pressure is reached.

Multiple expansion chambers may be used. The expansion chambers may be located in various positions and orientations with respect to the package. The expansion chamber may also be configured in various shapes, including handles, and display panels.

Embodiments of the present invention are also directed to a flexible package generally including a fitment or spout sealed in a panel. An aperture is defined in the package material and the spout is placed through the aperture from the inside or sealant side of the panel film, and then a flange of the fitment remaining inside the interior compartment can be sealed around the hole's edges.

The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 2 is a side cross-sectional schematic view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 3 is a perspective view of a package having multiple expansion chambers in accordance with an example embodiment of the present invention.

FIG. 4 is a side cross-sectional schematic view of a package having multiple expansion chambers in accordance with an example embodiment of the present invention.

FIG. 5 is a perspective view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 6 is a side cross-sectional schematic view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 7 is a perspective view of a package having multiple expansion chambers in accordance with an example embodiment of the present invention.

FIG. 8 is a side cross-sectional schematic view of a package having multiple expansion chambers in accordance with an example embodiment of the present invention.

FIG. 9 is a perspective view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 10A is a side cross-sectional schematic view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 10B is a side cross-sectional schematic view of the package of FIG. 10A showing the expansion chamber in an expanded state in accordance with an example embodiment of the present invention.

FIG. 11 is a perspective view of a package having an expansion chamber and handle aperture in accordance with an example embodiment of the present invention.

FIG. 12 is a side cross-sectional schematic view of a package having an expansion chamber and handle aperture in accordance with an example embodiment of the present invention.

FIG. 13 is a perspective view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 14A is a side cross-sectional schematic view of a package having an expansion chamber in accordance with an example embodiment of the present invention.

FIG. 14B is a side cross-sectional schematic view of the package of FIG. 14A showing the package filled with product in accordance with an example embodiment of the present invention.

FIG. 14C is a side cross-sectional schematic view of the package of FIGS. 14B showing the expansion chamber in an expanded state in accordance with an example embodiment of the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, cross-hatching, dashing or shading in the figures is provided to demonstrate sealed portions and/or integrated regions or devices for the package.

DETAILED DESCRIPTION

In the following descriptions, the invention will be explained with reference to various example embodiments; nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, embodiment, applications, or particular implementations described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration but not to limit the present invention. It should be appreciated that elements unrelated directly to the present invention are omitted from the embodiments and the attached drawings.

References to “top,” “bottom,” “front,” “back” and the like are for illustrative purposes only and are not meant to limit the scope of the disclosed invention. For instance, placing an expansion chamber on the “front” panel could be just as easily employed in the back or side portions of the package.

Referring to FIG. 1 and FIG. 2, the flexible package 100 comprises a front panel 102 and back panel 104, which define an interior compartment 106 accessible through an access opening. The edges 108 of the front 102 and back 104 panels are sealed together. However, one or more of the portions of the package 100 may be gusseted. For example, FIGS. 1 and 2 show a gusset 110 provided at the bottom of the package in order to create a larger volume within the interior compartment 106. Placing a gusset 110 on the bottom also provides the product with the ability to stand up on its own. Other panels, such as a side panel, could be gusseted as well.

A spout or fitment 112, such as a square top or inverted funnel shape, is provided to a portion of the top interface edge of the front 102 and back 104 panels. However, it is understood that the fitment could be located in various other positions and still be within the scope of the invention.

The package 100 further includes an expansion chamber 114 located or defined in the front panel 102 of the package. It is understood to be within the scope of the invention, however, that the expansion chamber may be located in any position on the package 100 such that it can communicate with the interior compartment 106. It is further within the scope of the invention to use multiple, or a plurality, of expansion chambers, each located such that they are capable of communicating with the interior compartment.

The expansion chamber 114 is shown extending the full width of the package, from side to side. However, the expansion chamber 114 may extend only partially across a dimension of the package 100. The expansion chamber may also be oriented horizontally, vertically or in any other direction.

A frangible seal, valve or other pressure sensitive closure 116 is disposed between the interior compartment 106 and the expansion chamber 114. The pressure sensitive closure 116 maintains separation between the interior compartment 106 and the expansion chamber 114. However, when the pressure in the interior compartment 106 rises above a predetermined threshold, the closure 116 will open or rupture to allow communication between the interior compartment 106 and the expansion chamber 114. The opening of closure 116 allows the product and/or gases located in the interior compartment 106 to have room to expand. Because of this added space within the package 100, the product and/or gas has a place to go and will therefore reduce pressure before leaking, rupturing, or other failure occurs.

The threshold pressure at which the closure 116 opens will depend on a variety of factors, including the type of film used to make the package and expansion chamber, the geometry of the package, and the size and geometry of the expansion chamber. In a few examples, the threshold may be approximately 5, 20 or 30 pounds per square inch (PSI). However, higher and lower threshold pressures are within the scope of the invention. As such, the package and corresponding expansion chamber can be configured to handle a wide range of pressures.

Referring to FIG. 3 and FIG. 4, the package 100 is shown having at least two expansion chambers 114. Each expansion chamber 114 is separated from the interior compartment 106 via a closure, valve or frangible seal 116. Each seal may be configured to rupture at the same or a different predetermined pressure. For example, a first seal may rupture at predetermined pressure P1. However, if the pressure in the package continues to rise, then the second seal may be set to rupture at a higher second predetermined pressure P2. Additional expansion chambers can be included to provide stepped control of internal pressure.

Referring to FIG. 5 and FIG. 6, the package 100 is shown having a vertically oriented expansion chamber 114 provided to the front panel 102. However, a similar expansion chamber may be provided to the back panel 104 in addition, or as an alternative to the front panel 102. It can also be seen in FIG. 5 that an additional top panel 118 may be provided between the top edges of the front 102 and back 104 panels to provide increased interior compartment volume. The top panel 118 can be gusseted or non-gusseted.

Referring to FIG. 7 and FIG. 8, the package 100 is shown having multiple expansion chambers 114. It is understood however, that any one or more of the depicted expansion chambers 114 may be omitted or re-located on the package 100 without departing from the scope of the invention. A generally flat gusset panel 120 is provided to the top of the package. The front 102 and back 104 panels seal at their respective interfaces with the top panel 120. An expansion chamber 120 extends outwardly from the front and back of the package at the interface between the top panel 120 and the respective front 102 and back 104 panels. Another expansion chamber 114 extends outwardly from the front panel 102.

The fitment 112 is provided (e.g., shown with cap) to an aperture in the top panel 120. Different sizes and shapes for the fitment can be employed. A flange 122 on the bottom of the fitment is sealed inside of the interior compartment 106 to provide a surface fitment configuration. In this configuration, when the pressure inside the package expands, it will generally push evenly around the seal of the flange 122 and no particular weak point will exist for leaking, as opposed to fitments that are sealed within or to the edge seals of panels or webs.

Referring to FIG. 9, FIG. 10A and FIG. 10B, the package 100 is shown having an expansion chamber 114 on the front panel 102. The expansion chamber 114 is configured to present a display graphic 124 on the package when the seal 116 separating the expansion chamber 114 from the interior compartment 106 ruptures. The expansion chamber 114 is shown collapsed in FIG. 10A and expanded in FIG. 10B. The size and shape of the expanded chamber may be chosen to correspond to the desired visual indication or graphic. For example, the expansion chamber may pop out or extend from the package with a message or an indication that the product has gassed off. The expansion chamber 114 may be located in various places on the package, for example front panel 102, back panel 104, top edge and side edges without departing from the scope of the invention. The expansion chamber may also comprise a variety of different shapes and sizes within the scope of the invention.

Referring to FIG. 11 and FIG. 12, the package 100 is shown having an expansion chamber 114 extending from a side edge. The expansion chamber 114 has an aperture 126 defined through it from front to back. As a result it can be used as a handle for carrying the package 100. The frangible seal 116 separates the expansion chamber 114 from the interior compartment 106 and functions as previously described. Once the frangible seal 116 is ruptured, the product contained in the interior compartment 106 will fill the expansion chamber 114, thereby making the handle easier and more comfortable for a person to grasp. A flange 122 on the bottom of the fitment is sealed inside of the interior compartment 106 to provide a surface fitment configuration. The diameter of the flange 122 is larger than the outer dimension of the cap. This configuration permits the fitment 112 to be sealed against the panel by placing a sealing device over the cap and contacting the panel while also contacting the flange 122 inside of the package.

In use, the interior compartment of the flexible package can be filled to the top with the product. Doing this forces any unwanted oxygen out of the interior compartment. Then the package is sealed. Thereafter, if the product contained in the package gasses off, the gasses raise the pressure inside of the package until a predetermined pressure is reached. When the predetermined pressure is reached, the frangible seal, or other pressure-sensitive closure means, separating the expansion chamber form the interior compartment opens, thereby increasing the volume of the package. The result is a decrease in the pressure in the package proportional to the volume of the expansion chamber. One or more expansion chambers may be provided. The expansion chambers may be of any desired size or configuration. When more than one expansion chamber is provided, their individual opening pressures may all be the same, or the may be staged. In addition, the expansion chambers as disclosed and depicted herein, can be employed or provided with packages other than just flexible packages, including packages constructed at least partially of rigid, semi-rigid, or semi-flexible materials or panels.

It is also contemplated that expansion chambers may also have secondary expansion chambers in communication with the primary expansion chamber. A pressure sensitive closure is used to separate the primary and secondary expansion chambers. The closure is configured to open communication with the secondary expansion chamber at a pressure higher than the closure separating the interior compartment from the primary expansion chamber.

The construction of a flexible package is generally described in U.S. patent application Ser. No. 12/400,304, which is hereby incorporated by reference in its entirety. Briefly, the package panel portions are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes or polypropylenes laminated with other materials such as nylon, polyester, and like films. To provide for increased barrier properties, embodiments can use composite or laminate layers of said materials and material of the like. Generally, in such composite or laminate embodiments, a material having preferred sealing characteristics can be joined, bonded or laminated to a material having a different preferred characteristic (e.g., beneficial oxygen barrier properties). Regardless, single sheets, composites/laminates, and a myriad of other materials and techniques known to one skilled in the art may be implemented based on particular usage and manufacturing needs without deviating from the spirit and scope of the present invention. The present invention in certain embodiments permits the flexible package to be made using cheaper materials than would otherwise be necessary because the expansion chamber addresses the danger of pressure induced failure.

In an additional embodiment, the pressure sensitive closure used is selected to maintain a predetermined maximum pressure in the package. Thus, if pressure increases over the threshold, then gas is released into the expansion chamber until the pressure in the package falls below the threshold pressure. When such condition is achieved, the pressure sensitive closure closes or re-seals. This configuration is particularly useful when the contents of the package are to be maintained under relatively constant pressure.

In a further embodiment as shown in FIGS. 13 and 14A-14C, the expansion chamber 114 may be provided with a film or web of elastic material to form an expandable web 128 that functions as the pressure sensitive closure. The expandable web has an elastic property such that it has a measurable resistance to the interior compartment 106 being filled with gas or package contents. In such an arrangement, an increase in pressure in the main compartment causes the closure to stretch into the expansion chamber, thereby increasing the volume of the package and correspondingly lowering the pressure in the package. If the pressure in the package recedes, then the resilient film returns to the its original state. This arrangement permits the expansion chamber to be constructed of the same material(s) as the rest of the package, thus reducing manufacturing cost.

In the arrangement described above, the expansion chamber 114 does not flood with gas or contents, and a corresponding immediate drop of pressure in the interior compartment 106 does not occur. Instead, the web 128 expands into the expansion chamber 114 in proportion to the rise in pressure within the interior compartment 106 and a relatively constant pressure can be maintained within a set range of expansion volume. This arrangement is particularly beneficial, for example, when the contents of the package is under pressure or has gas mixed with a liquid. In one example, a carbonated beverage could be maintained under pressure, and when some of the carbon dioxide in the liquid gasses off, the gas pressure expands the web, thereby increasing the relative pressure inside of the interior compartment, but the expansion allows regulation of that pressure so that the package does not rupture. The increased pressure coupled with the resilient nature of the web trying to return to its memorized or equilibrium state will promote the liquid reabsorbing the carbon dioxide that was previously gassed off. As a result, the freshness of the package contents is maintained.

Referring particularly to FIGS. 14A-14C, the operation of an expandable web 128 can be seen. In FIG. 14A, the package 100 has not been filled yet. FIG. 14B shows the package 100 after the interior compartment or chamber 106 is filled. The product is filled to a fill line 132 as shown in the figure. The web 128 has not yet expanded into the expansion chamber 114. Now in FIG. 14C, the contents of the package has produced gas, causing a gas pocket 134 to form above the product fill line 130, thereby stretching the expandable web 128 into the expansion chamber 114, and in the neck region 136 of the package 100. In one particular alternative, the expansion chamber may be omitted, wherein the expandable web 128 maintains the sealed integrity of the package.

It is also contemplated that a pressure sensitive closure separating the expansion chamber(s) can be omitted with the use of resilient expansion chambers or elastic webs. In such configurations, the resilient property of the expansion chamber or web functions as the pressure regulation means.

Each package panel can be formed from an individual web or, alternatively, each of the panels can be portions of a larger single web, wherein the large web is folded, cut or shaped to define the individual and distinct panel portions and, ultimately, the shape and size of the package 100. Further, in one embodiment, the top and bottom panel portions can be formed by the selective joining of the respective end portions of the front and back panels to provide necessary material for folding and formation. Regardless of the formation techniques, or the use of separate web panels, a designated and distinguishable panel portion is defined for each panel. Further, one or more of the panel portions can be gusseted.

The package 100 and its portions can be formed to provide a stand-up pouch, pre-made pouch, bag-top, one formed and filled on a “form-fill-seal” (e.g., vertical, horizontal, etc.) machine, thermoforming machine, and other known package designs and configurations. Other known package designs and packaging techniques and features can be adapted to incorporate or form the configuration of the present invention as well. The fitment or access device 112 can be provided to the package 100 during the machining or formation process, or pre-applied to a section of material or web prior to package formation.

Embodiments employing seals can utilize heat seals, adhesive bonding, and various other known sealing techniques.

Various figures and descriptions disclose features and accessories. However, it must be noted that these features are merely illustrative in nature and may be placed in varying locations and under varying configurations, and still be consistent with the present invention. Various regions of the package can include a handle portion, access devices (e.g., re-closeable zipper devices), and the like. In addition, the shape and configuration for the panel portions are also merely illustrative and can be altered without deviating from the spirit and scope of the present invention. Any of the panel portions, or selected regions thereof, can include various aesthetic and functional graphics, such as logos, instructions, advertising, bar codes, and the like. These graphics can run transverse, parallel, or even in a diagonal orientation to the longitudinal panel edges discussed herein.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing/forming the present invention to those specifically defined herein. A myriad of various unspecified steps and procedures can be performed to create or form the inventive package 100. In addition, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention. 

1. A flexible package, comprising: a first panel; a second panel disposed opposite the first panel; an interior compartment disposed between the first and second panels; a first expansion chamber disposed adjacent to the interior compartment; and a first pressure sensitive closure separating the first expansion chamber from the interior compartment and configured to permit the interior compartment to expand into the first expansion chamber when a first pressure value of the interior compartment is exceeded.
 2. The flexible package of claim 1, further comprising a fitment disposed in the package, the fitment having a top portion protruding outward from the package and a bottom portion protruding into the package.
 3. The flexible package of claim 2, further comprising a flange disposed on the bottom portion of the fitment and sealed inside of the interior compartment.
 4. The flexible package of claim 1, wherein the first expansion chamber is configured as a handle.
 5. The flexible package of claim 1, further comprising a second expansion chamber disposed adjacent to the interior compartment and separated from the interior compartment by a second pressure sensitive closure, the second pressure sensitive closure configured to permit the interior compartment to expand into the second expansion chamber when a second pressure value of the interior compartment is exceeded.
 6. The flexible package of claim 5, wherein the first pressure value is the same as the second pressure value.
 7. The flexible package of claim 1, wherein the first pressure sensitive closure is an expandable web.
 8. The flexible package of claim 1, wherein the first pressure sensitive closure is a frangible seal
 9. The flexible package of claim 1, wherein the first expansion chamber displays a message when in communication with the interior compartment.
 10. A flexible package, comprising: a first panel; a second panel disposed opposite the first panel; an interior compartment disposed between the first and second panels; a first expansion chamber disposed adjacent to the interior compartment; and an expandable film separating the first expansion chamber from the interior compartment, the expandable film configured to expand into the first expansion chamber in response to a first pressure value of the interior compartment exceeding a threshold value.
 11. The package of claim 10, wherein the first and second panels are constructed of a generally flexible polymer material.
 12. The package of claim 10, further comprising a gusset extending between the first and second panels.
 13. The flexible package of claim 10, further comprising an access device disposed in the package, the access device having a top portion protruding outward from the package and a bottom portion protruding into the package.
 14. The flexible package of claim 13, further comprising a flange disposed on the bottom portion of the access device and sealed inside of the interior compartment.
 15. The flexible package of claim 10, further comprising a second expansion chamber disposed adjacent to the interior compartment and separated from the interior compartment by a pressure sensitive closure.
 16. The flexible package of claim 15, wherein the pressure sensitive closure is an expandable web.
 17. A method for containing gas produced by a contents of a flexible package, the method comprising: activating a pressure sensitive closure separating an expansion chamber from an interior compartment of the flexible package in response to an increase in pressure in the interior compartment above an activation value.
 18. The method of claim 17, wherein the step of activating the pressure sensitive closure includes rupturing a frangible seal.
 19. The method of claim 17, wherein the step of activating the pressure sensitive closure includes stretching a flexible film.
 20. The method of claim 17, further comprising communicating the contents of the interior compartment with expansion chamber, thereby lowering the pressure in the interior compartment. 